Plate edge protector

ABSTRACT

An edge protector  1  mountable to a cathode plate  2 , the edge protector  1  comprising a set of elongate channels  3 . Each elongate channel  10, 20, 30  defining a slot. The set of elongate channels  3  including a first and second channel  10, 20  adapted to receive and cover respective side edges  4   a,    4   c  of the cathode plate  2 , and a third channel  30  adapted to receive and cover a lower edge  4   b  of the cathode plate  2 . The first, second and third channels  10, 20, 30  being channels of a first, second and third body  12, 22, 32  respectively. Wherein, the edge protector  1  further includes a first and a second insert  40   a - b . The first insert  40   a  being adapted to be inserted into or over a feature  14  of a first end  16   a  of the first body  12  and a feature  24   a  of a first end  26   a  of the second body  22  to form a first corner  6   a . The second insert  40   b  being adapted to be inserted into or over a feature  24   b  of a second end  26   b  of the second body  22  and a feature  34  of a first end  36   a  of the third body  32  to form a second corner  6   b . The first and second corners  6   a - b  are overmoulded with a first and second mouldable material respectively. The first corner  6   a  being separately overmoulded to the second corner  6   b.

FIELD OF INVENTION

This invention relates to a plate edge protector. More particularly, this invention relates to a plate edge protector mountable to a plate acting as a cathode for metal refining.

BACKGROUND ART

The following references to and descriptions of prior proposals or products are not intended to be, and are not to be construed as, statements or admissions of common general knowledge in the art. In particular, the following prior art discussion should not be assumed to relate to what is commonly or well known by the person skilled in the art, but to assist in the inventive process undertaken by the inventor(s) and in the understanding of the invention.

Plates are used as a cathode in refining metal out of a solution with fine metal particles or compounds with metal in them. Metal can build up on and near edges of the plates making it hard to remove the plates from a housing. Edge protectors are placed on the edges of the plates to stop build-up of the metal on or near the edges. Edge protectors have been described with structurally inadequate corners and insufficient sealing to stop the solution entering the region of and surrounding the edges.

An object of the present invention is to ameliorate one or more of the aforementioned disadvantages of the prior art or to at least provide a useful alternative thereto.

STATEMENT OF INVENTION

The invention according to one or more aspects may be as defined in the independent claims. Some optional and/or preferred features of the invention are defined in the dependent claims.

Accordingly, in one aspect of the invention there is provided:

An edge protector mountable to a cathode plate, the edge protector comprising a set of elongate channels, each elongate channel defining a slot, the set of elongate channels including a first and second channel adapted to receive and cover respective side edges of the cathode plate, and a third channel adapted to receive and cover a lower edge of the cathode plate, the first, second and third channels beings channels of a first, second and third body respectively, wherein:

-   -   the edge protector further includes a first and a second insert,         the first insert being adapted to be placed into or over a         feature of a first end of the first body and a feature of a         first end of the second body to form a first corner, the second         insert being adapted to be placed into or over a feature of a         second end of the second body and a feature of a first end of         the third body to form a second corner; and     -   the edge protector further includes first and second corner over         mouldings adapted to seal the first and second corners, the         first corner over moulding being separate to the second corner         over moulding.

Edge Protector

The edge protector may be made of materials including plastic, ceramic, rubber, metal, silicone and/or a composite. The edge protector may be made of materials including carbon fibre, fibre glass or other composite materials. The edge protector may be made of materials including glass, clay ceramic or other ceramic materials. Preferably, the edge protector is made of polymeric materials resistant to electrolytic solutions. The edge protector may be substantially made of polyvinyl chloride (PVC) or acrylonitrile-butadiene-styrene (ABS), or a composite of suitable polymers.

Cathode Plate

The cathode plate may be made of materials including any metal. The cathode plate may be made of any metal with sufficiently unreactive properties in response to a solution for the cathode plate and to exposure to electric current. The cathode plate may be made substantially of any metal. Preferably the cathode plate is substantially made of either stainless steel or aluminium. The stainless steel or aluminium may have minimal impurities, such that the cathode plate is made substantially of pure stainless steel or aluminium. The cathode plate may be non-planar, such as curved. Preferably, the cathode plate is flat or planar on either facing surface. Preferably, the cathode plate is a thin plate. The cathode plate may be any thickness. Preferably, the cathode plate is between 2 mm and 10 mm thick. Most preferably, the cathode plate is between 2 mm and 5 mm thick. The cathode plate may be any width and length. Preferably, the cathode plate is between 500 mm and 1000 mm in width. Preferably, the cathode plate is between 500 mm and 1500 mm in length. The cathode plate is ideally polygonal, with at least three clear edges. Preferably, the cathode plate is rectangular, with two parallel side edges and a joining straight edge at right angles to the side edges.

The cathode plate may include holes, other cut outs and/or regions with different thicknesses. The cathode plate may include elbows or other shapes. Preferably, the cathode plate includes holes and other cut outs. The holes may be located along the edges of the cathode plate. Preferably, the holes are located along the side edges of the cathode plate. Preferably, the other cut outs include cuts outs on the sections of the plate which the first and second corners cover. Preferably, there are also cut outs on an upper edge of the cathode plate. Preferably, the cathode plate includes holes to receive bolts for attachment of the edge protector to the cathode plate. The cathode plate may include supports, handles or other devices attached to a main plate of the cathode plate.

The cathode plate, with the edge protector may be adapted for insertion into a solution or matrix. The solution may include metal ions, metal or compounds including metal. The metal may be any metal. The metal may be zinc or cobalt. Preferably, the compounds including metal include copper oxide and/or copper sulphate. Preferably, the cathode plate is adapted to be used as a cathode in that electrons are pumped into the cathode plate. Preferably, the cathode plate is adapted to be placed next to an anode plate. Preferably, electrons are pumped away from the anode plate. Preferably, the solution acts as an electrolyte. Preferably, the edge protector and cathode plate are adapted for use in electrorefining or electrolysis. Most preferably, the edge protector and cathode plate are adapted for use in copper, zinc or cobalt electrorefining. Preferably, the copper oxide and/or copper sulphate compounds are split to form in part copper ions. Preferably, the cathode plate and edge protector are adapted so that the copper ions are deposited onto the cathode plate in the electrorefining process. Preferably, the materials deposited onto the cathode plate form above 98% pure copper.

Elongate Channels

The set of elongate channels (elongate channels) may be curved to follow a curved edge of the cathode plate. Preferably, the elongate channels are linear. The elongate channels may have the same cross-sectional profile along the length of each elongate channel. The elongate channels may include transverse holes or other features. Preferably, the elongate channels have the substantially the same cross-sectional profile along the length of each elongate channel Substantially in that, preferably, the elongate channels also include transverse holes. The transverse holes may be any diameter. Preferably, the transverse holes are between 3 mm and 15 mm in diameter. Most preferably, the transverse holes are between 5 mm and 9 mm in diameter.

The elongate channels may include any transverse cross-sectional shape. The elongate channels may include transverse cross-sections with square or rectangular shapes. The elongate channels may include a substantially T-shaped transverse cross-section. Substantially in that the T-shaped transverse cross-section may also include features, holes, tapers and radiused corners. Preferably, the elongate channels include a substantially cruciform transverse cross-sectional shape. Substantially in that the cruciform shape may also include features, holes, tapered edges, radii and other features. Preferably, the elongate channels include a taper on a first end of the elongate channel. The first end of the elongate channel may be an open end of the elongate channel which the cathode plate is inserted into. Preferably, the taper is angled such that the elongate channel is thinner where the elongate channel is open compared to a region further into the elongate channel. The open end of the elongate channel may be between 0 mm and 3 mm thinner than the thickness of the cathode plate. The open end of the elongate channel may be between 0 mm and 5 mm thicker than the thickness of the cathode plate. The open end of the elongate channel may the same thickness as the thickness of the cathode plate. Preferably, internal edges of the transverse cross-sectional shape of the elongate channels have radii. The internal corners of the transverse cross-sectional shape of the elongate channels may include grooves shaped and adapted such that edges of the cathode plate do not contact the first, second and third bodies when the cathode plate has been inserted into the elongate channels. The grooves may include any shaped profile. The grooves may include square shaped, rectangular and circular profiles.

Preferably, the cruciform transverse cross-sectional shape of the elongate channels allows for retaining strips to be inserted in opposite outer slots of the elongate channels. Preferably, the opposite outer slots form two of four ends of the cruciform cross-sectional shape. Preferably, the opposite outer slots are adapted to extend outwards normal to large faces of the cathode plate when the cathode plate is inserted into the elongate channels. The opposite outer slots may form a channel which is any width and thickness. The large faces of the cathode plate may include a first large face and a second large face. Preferably, the sealing strips and opposite outer slots are positioned such that the sealing strips contact the first and second large face of the cathode plate and are adapted to prevent or limit the solution from contacting the side edges and lower edge of the cathode plate.

First, Second and Third Channels and Bodies

The first, second and third channels (channels) may include different transverse cross-sections. The first and third channels may include the same transverse cross-sections which is different to the second channels transverse cross-section. Preferably, the first, second and third channels all have substantially the same transverse cross-section.

The edge protector may not be symmetrical. The edge protector may be symmetrical in that a first side edge of the cathode plate can be inserted into either the first channel or the third channel. The edge protector may be symmetrical about a transverse plane half way along the second channel. The edge protector may be symmetrical about a transverse plane half way along the second channel.

The longitudinal length of the first, second and third channels may be different. Preferably, the longitudinal length of the first and third channels are the same.

Preferably, the longitudinal length of the first and third channels are different to the longitudinal length of the second channel. The longitudinal length of the first, second and third channels may be any length. The longitudinal length of the first, second and third channels may be between 100 mm and 5 m. The longitudinal length of the first, second and third channels may be between 500 mm and 2 m. Preferably, the longitudinal length of the first and third channels is between 900 mm and 1300 mm Preferably, the longitudinal length of the second channel is between 800 mm and 1200 mm Preferably, the longitudinal length of the first, second and third channels is long enough to cover the side and lower edges of the cathode plate that is adapted to be exposed to the solution or matrix.

The first, second and third channel bodies (bodies) may be extruded bodies. The bodies may include a substantially uniform transverse cross-sectional shape along their length. Substantially in that the bodies may also include tapers, chamfers, radiused corners and holes.

The first and second ends of the first, second and third bodies may be substantially identical or different. Preferably, the first and second ends of the second body are the substantially identical. The features in the ends of the first, second and third bodies to receive inserts may include holes, extrusions and other shapes. Preferably, the first and third bodies each include an extrusion and/or hole in the first end of the first and third bodies which are adapted to receive the inserts. Most preferably, the first and third bodies each include a hole in the first end of the first and third bodies which are adapted to receive the inserts. Preferably, the second body includes an extrusion and/or hole in a first and second end of the second body which are adapted to receive the inserts. Most preferably, the second body includes a hole in a first and second end of the second body which are adapted to receive inserts.

Preferably, the holes in the ends of the first, second and third bodies have a transverse cross-section area larger than the channels. The holes may include substantially cylindrical holes, square/rectangular shaped holes, cruciform shaped holes, gear shaped holes or other shaped holes. Preferably, the holes include substantially cylindrical holes. Preferably, the inserts include cylindrical extrusions which are adapted to fit or press fit into the cylindrical holes. The features may include axial stubs or extrusions. The features may include cylindrical ring-shaped extrusions. The features may include other shaped extrusions.

Thicknesses of walls of the bodies may be adapted to be thin enough to allow open ends of the channels to act as movable cantilevered springs. The cantilevered springs may be adapted to be a stiffness which allows insertion of the cathode plate and also for the open ends of the channels to apply a force clamping down onto the cathode plate.

First and Second Inserts

Each of the first and second inserts (inserts) may be made of multiple pieces. Preferably, the first insert is made of a single piece and the second insert is made of a single piece. The inserts may be manufactured using a 3D printing method. The inserts may be manufactured using a machining process such as using a CNC (computer numerical control) machine.

The inserts may be manufactured using a moulding process. The inserts may be made of materials including suitable plastic, ceramic and/or a composite. The inserts may be made of PVC or ABS.

The first and second inserts may be different. The first and second inserts may be substantially the same. Substantially being, they may have differences such as additional radii or tapers. Preferably, the first and second inserts are identical.

Preferably, the first insert is adapted to be placed into a feature of the first end of the first body and the feature of the first end of the second body to form the first corner. Preferably, the second insert is adapted to be placed into the feature of the second end of the second body and the feature of the first end of the third body to form the second corner.

The first insert may be adapted to be inserted into a feature of the first end of the first body and the feature of the first end of the second body to form the first corner. The second insert may be adapted to be inserted into the feature of the second end of the second body and the feature of the first end of the third body to form the second corner.

The first and second inserts may include a bend at any angle. The first and second inserts may include a bend between 80 and 100 degrees. Preferably, the first and second inserts may include a 90 degree bend. The first and second inserts may include insert slots. Each of the first and second inserts may include a first and second slot (slots). Preferably, a longitudinal axis of the first slot may be orientated at 90 degrees to a longitudinal axis of the second slot. Preferably, the first and second slot meet to form an elbow slot. A transverse cross-section of the slots may include the same transverse cross-section as the first, second and/or third channels. Preferably, the transverse cross-section of the slots is different to the transverse cross-section of the first, second and/or third channels. Preferably, the transverse cross-section of the slots is substantially rectangular. Preferably, a first end of the transverse cross-section of the slots is enclosed and a second end is open. Preferably, the first and second slots are adapted so that the cathode plate is inserted into the open second end of the slots.

Preferably, the first and second slots are slots of a first and second arm respectively. An end of each of the first and second arms may include features, such as extrusions and tapers. The extrusions may include any shape. The extrusions may include cylinders, T-shaped extrusions and/or cruciform extrusions. Preferably, the end of each of the first and second arms include cylinder shaped extrusions. Preferably, the cylinder-shaped extrusions have a larger diameter than the dimensions of the slots in the inserts. Preferably, the cylinder-shaped extrusions are adapted to fit or press fit into the holes in the ends of the first, second and third channels with holes. The holes in the end of the first and second arms may be any shaped holes. The holes in the end of the first and second arms may be T-shaped, cruciform and/or cylindrical. The holes may be shaped and sized to fit or press fit onto the features on the ends of the first, second and third bodies. Extrusion features of the bodies may be inserted into holes in the first and second arms.

First and Second Corners

Preferably, the process of over moulding the first and second corners may include use of a frame. Preferably, the process of overmoulding the first and second corners includes installing a temporary brace (the frame) to hold the corners at right angles and the slots of the first and second inserts aligned with the first, second and third channels. Preferably, the process further includes placing the frame and/or the first and second corners into at least one mould (which may include dies and inserts). Preferably, then using methods including injection moulding and/or other moulding processes to overmould the first and second corners.

Alternatively, the process of overmoulding the first and second corners may include placing composite materials such as fibre glass or carbon fibre with a glue such as epoxy over the first and second corners. This alternate process may include a vacuum forming method.

The material which is overmoulded on the first and second corners may be plastic or a composite such as fibre glass. The plastic may be any suitable plastic. The plastic may be PVC or ABS. The material which is overmoulded on the first and second corners may be the same material which the first, second and third bodies are substantially made of. The material which is overmoulded on the first and second corners may be the same material which the first and second inserts are made of.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be better understood from the following non-limiting description of preferred embodiments, in which:

FIG. 1 is a front exploded view of an edge protector and a cathode plate according to any one of a first, second, third and fourth embodiment of the invention.

FIG. 2 is a front assembled view of the edge protector mounted to the cathode plate according to any one of the first, second, third and fourth embodiment of the invention.

FIG. 3 is a front view of a first and third body according to any one of the first, second, third and fourth embodiment of the invention.

FIG. 4 is an end cross-sectional view of a first end of the first body, first and second end of a second body and first end of the third body according to the first or second embodiment of the invention.

FIG. 5 is an end cross-sectional view of a second end of the first body or a second end of the third body according to the first or second embodiment of the invention.

FIG. 6 is a front cross-sectional view of a first and second insert according to the first or third embodiment of the invention.

FIG. 7 is a front view of the first and second insert according to the first or third embodiment of the invention.

FIG. 8 is a perspective view of the first and second insert according to the first or third embodiment of the invention.

FIG. 9 is a front view of overmoulded first and second corners according to any one of the first, second, third and fourth embodiment of the invention.

FIG. 10 is an upper perspective view of the overmoulded first and second corners according to any one of the first, second, third and fourth embodiment of the invention.

FIG. 11 is a lower perspective view of the overmoulded first and second corners according to any one of the first, second, third and fourth embodiment of the invention.

FIG. 12 is a perspective view of the first and second corners according to any one of the first, second, third and fourth embodiment of the invention.

FIG. 13 is a side view of a first and second insert according to either the second or fourth embodiment of the invention.

FIG. 14 is an end cross-sectional view of the second end of the first body or a second end of the third body according to either a third or fourth embodiment of the invention.

FIG. 15 is an end cross-sectional view of the first end of the first body, the first and second end of the second body and the first end of the third body according to either a third or fourth embodiment of the invention;

FIG. 16 is an illustration of a brace moulding plate slotted into an edge protector according to one embodiment;

FIG. 17 is a sectional perspective view of a corner section according to one embodiment; and

FIG. 18 is an illustration of a front view of a brace moulding plate according to the embodiment shown in FIG. 16.

DETAILED DESCRIPTION OF THE DRAWINGS

Preferred features of the present invention will now be described with particular reference to the accompanying drawings. However, it is to be understood that the features illustrated in and described with reference to the drawings are not to be construed as limiting on the scope of the invention.

An edge protector 1 mountable to a cathode plate 2, the edge protector 1, 101, 201, 301 comprising a set of elongate channels 3, 103. Each elongate channel 10, 20, 30, 110, 120, 130 defining a slot. The set of elongate channels 3 including a first and second channel 10, 20, 110, 120 adapted to receive and cover respective side edges 4 a, 4 c of the cathode plate 2, and a third channel 30, 130 adapted to receive and cover a lower edge 4 b of the cathode plate 2. The first, second and third channels 10, 20, 30, 110, 120, 130 being channels of a first, second and third body 12, 22, 32, 112, 122, 132 respectively. Wherein, the edge protector 1 further includes a first and second insert 40 a-b, 140 a-b. The first insert 40 a, 140 a being adapted to be placed into or over a feature 14 of a first end 16 a of the first body 12, 112 and a feature 24 a of a first end 26 a of the second body 22, 122 to form a first corner 6 a. The second insert 40 b being adapted to be placed into or over a feature 24 b of a second end 26 b of the second body 22, 122 and a feature 34 of a first end 36 a of the third body 32, 132 to form a second corner 6 b. The first and second corners 6 a-b are overmoulded with a first and second mouldable material respectively. The first corner 6 a being separately overmoulded to the second corner 6 b.

Like features may be referenced with the same reference number. For example, the first and second corners 6 a-b in each of a first, second, third and fourth embodiment are slightly different in some embodiments but are all referenced 6 a-b. Furthermore, like features may be referenced with like reference numbers. A first, second, third and fourth embodiment of the invention include combinations of two versions of the first, second and third channels 10, 20, 30, 110, 120, 130 (channels) and two versions of the first and second inserts 40 a-b, 140 a-b (inserts). The first embodiment of the invention includes a first version version of the channels 10, 20, 30 shown in FIGS. 4 and 5 with a first version of the inserts 40 a-b shown in FIGS. 6 to 8. The second embodiment of the invention includes the first version of the channels 10, 20, 30 with a second version of the inserts 140 a-b shown in FIG. 13. The third embodiment of the invention includes a second version of the channels 110, 120, 130 shown in FIGS. 14 and 15 with the first version of the inserts 40 a-b. The fourth embodiment of the invention includes the second version of the channels 110, 120, 130 with the second version of the inserts 140 a-b.

The following passages refer to any one of a first, second, third or fourth embodiment of the invention. The first and third bodies 12, 32, 112, 132 are identical. The first, second and third channels 10, 20, 30, 110, 120, 130 are substantially the same. The channels 10, 20, 30, 110, 120, 130 have an inner transverse cross-section which is substantially cruciform shape 10 a, 110 a (as seen in FIGS. 4 to 5 and FIGS. 14 to 15). Substantially in that the cruciform shape also includes radii and tapers.

The following passages refer to either the first or second embodiment of the invention. The cruciform shape includes four ends; a top end 10 b, two side ends 10 c-d and a bottom end 10 e. The top end 10 b includes tapers 10 f angled outwards from a smaller width base 10 bi of the top end 10 b to a larger width top 10 bii of the top end 10 b. The larger width top 10 bii of the top end 10 b includes radiused edges 10 g. The two side ends 10 c-d include radiused upper edges 10 h with larger radii and radiused lower edges 10 i with smaller radii. Furthermore, lowers faces 10 j of the two side ends 10 c-d include tapers 10 n. The tapers 10 n extend inwards from a smaller width inner side 10 ci of each of the two side ends 10 c-d to a larger width outer side 10 cii of the two side ends 10 c-d. The top end 10 b and two side ends 10 c-d are enclosed. The bottom end 10 e is open or not enclosed by the first, second and third bodies. The bottom end 10 e includes tapered faces 10 k extending from a smaller width base 10 ei of the bottom end 10 e to a larger width top 10 eii of the bottom end 10 e. The tapered faces 10 k of the bottom end 10 e include edges 10 m on the smaller width base 10 ei which are adapted to contact the large faces of the cathode plate 2 when the cathode plate 2 is inserted into the channels 10, 20, 30. The edges 10 m limit the flow of a solution into the channels 10, 20, 30.

The following passages refer to either the third or fourth embodiment of the invention. The cruciform shape includes four ends; a top end 110 b, two side ends 110 c-d and a bottom end 110 e. The top end 110 b includes cylindrical slots 110 f cut into two upper corners 110 bi of the top end 110 b. The top end 110 b is adapted such that edges 4 a-c of the cathode plate 4 a-c do not contact the bodies 112, 122, 132 when the cathode plate 2 is inserted into the edge protector 1. The adaptions include the cylindrical slots 110 f. The top end 110 b includes a top 110 bii. The bottom end 110 e includes tapered faces 110 k extending from a smaller width base 110 ei of the bottom end 110 e to a larger width top 110 eii of the bottom end 110 e. The tapered faces 110 k of the bottom end 110 e include edges 110 m on the smaller width base 110 ei which are adapted to contact the large faces of the cathode plate 2 when the cathode plate 2 is inserted into the channels 110, 120, 130. The edges 110 m limit the flow of a solution into the channels 110, 120, 130. The two side ends 110 c-d are substantially rectangular slots.

Unless otherwise stated, the following passages refer to any of the first, second, third and fourth embodiments of the invention. The edge protector 1, 101, 201, 301 and cathode plate 2 are adapted for insertion into the solution. The solution may include any metal. Preferably, the solution includes either copper, zinc or cobalt. The copper, zinc or cobalt may be in an oxidised form or in the form of another compound including copper, zinc or cobalt. A plate portion 2 a of the cathode plate is made of either stainless steel or aluminium. The tapers 10 k, 10 n described above may also include curved faces and curved tapers.

The features 14, 24 a-b, 34 of the first, second and third bodies 12, 22, 32, 112, 122, 132 (bodies) are substantially identical. The features 14, 24 a-b, 34 of the first or second embodiment of the invention are shown in FIG. 4. The features 14, 24 a-b, 34 of the second and third embodiment of the invention are shown in FIG. 15. The features 14, 24 a-b, 34 include a cylindrical hole 18 with a longitudinal axis aligned substantially parallel with a longitudinal axis of the first, second and third channels 10, 20, 30, 110, 120, 130. The cylindrical holes 18 only extend part way into the bodies 12, 22, 32, 112, 122, 132. Preferably, the cylindrical holes 18 extend between 0 mm and 5 mm further than the distance the inserts 40 a-c extend into the cylindrical holes 18. The cylindrical holes 18 may include tapers, radius edges and chamfered edges. Preferably, the cylindrical holes 18 are in the shape of a regular cylinder. Preferably, the diameter of the cylindrical holes 18 is between 5 mm smaller and 5 mm larger than the diameter of features on the first and second inserts 40 a-b, 140 a-b which are adapted for insertion into the cylindrical holes 18. The first and second inserts 40 a-b, 140 a-b may be a press fit into the cylindrical holes 18. The cylindrical holes 18 may be any diameter. The cylindrical holes 18 may be between 5 mm and 30 mm in diameter. Preferably, the cylindrical holes 18 are between 13 mm and 19 mm in diameter.

End faces 11 of the ends of the bodies 10, 20, 30, 110, 120, 130 are substantially flat. The bodies 12, 22, 32, 112, 122, 132 further include holes 72 in the ends of the channels 10, 20, 30, 110, 120, 130 without the features 14, 24 a-b, 34. The holes 72 are located in the second end 16 b of the first body 12, 112 and second end 36 b of the third body 32, 132. Outer surfaces 70 of the bodies 12, 22, 32, 112, 122, 132 are rounded. A transverse cross-section of the outer surfaces 70 of the bodies 12, 22, 32, 112, 122, 132 are in the shape of a rectangle with rounded corners.

The following refers to the first and second inserts 40 a-b according to the first and third embodiments of the invention. The first and second inserts 40 a-b (inserts) are in the shape of a 90 degree elbow. The first and second inserts 40 a-b are identical. The inserts 40 a-b each include a slot 41. The slot 41 is a rectangular slot with a closed end 42 a and an open end 42 b. The open end 42 b is adapted to receive the cathode plate 2. The slot 41 is within 20% of the thickness of the top end 10 b and bottom end 10 e of the first, second and third channels 10, 20, 30, 110, 120, 130. The inserts 40 a-b are adapted such that when they are inserted into the first, second and third channels 10, 20, 30, 110, 120, 130 a top 42 ai of the closed end 42 a of the slot 41 is within 5 mm of lining up with the top 10 bii, 110 bii of the top end 10 b, 110 b of the first, second and third channels 10, 20, 30, 110, 120, 130. Preferably, within 2 mm of lining up. The closed end 42 a of the slots 41 of the inserts 40 a-b have radiused edges. The slots 41 include a 90 degree bend. The slots 41 are adapted to be aligned with the top and bottom ends 10 b, 10 e, 110 b, 110 e of the channels 10, 20, 30, 110, 120, 130 when the inserts 40 a-b are inserted into the bodies 12, 22, 32, 112, 122, 132.

The 90 degree elbow of the inserts 40 a-b include two arms 43 a-b. The two arms 43 a-b orientated at 90 degrees to each other. Each of the two arms 43 a-b include a feature 44 a-b (insert feature). The features 44 a-b are in the form of cylinders 44 a-b. The cylinders 44 a-b are adapted for insertion into the features 14, 24 a, 24 b, 34 of the bodies 12, 22, 32, 112, 122, 132. At inner ends 48 a-b of the cylinders 44 a-b the inserts 40 a-b include a surface 49 a-b which is adapted to contact the ends of the bodies 12, 22, 32, 112, 122, 132 when the inserts 40 a-b are inserted into the features 14, 24 a, 24 b, 34 of the bodies 12, 22, 32, 112, 122, 132.

FIG. 1 shows an exploded view of the components of the edge protector 1 and the cathode plate 2. The moulded bodies 50, 60 shown in FIG. 1 are adapted not the be separated from the other components of the edge protector 1 and are only shown in the exploded view for clarity. All the components of the edge protector 1 are made of either PVC or ABS. The assembly of the components of the edge protector 1, 101, 201, 301 is as follows. A first cylinder 44 a of the first insert 40 a is inserted into the feature 14 of the first end 16 a of the first body 12, 112. A second cylinder 44 b of the first insert 40 a is then inserted into the feature 24 a of the first end 26 a of the second body 22, 122. This completes the first corner 6 a.

A first cylinder 44 b of a second insert 40 b is then inserted into the feature 24 b of the second end 26 b of the second body 22, 122. A second cylinder of the second insert 40 b is then inserted into the feature 34 of the first end of the third body 32, 132. This completes the second corner 6 b.

A brace 80 is then inserted into the channels 10, 20, 30, 110, 120, 130 and slots 41 as seen in FIGS. 16 and 17. The regions 80 a of the brace 80 which are inserted into the channels 10, 20, 30, 110, 120, 130 have the same thickness as the cathode plate 2. The thickness of the cathode plate is 2.7 mm. The brace 80 is made of steel plate. The brace 80 holds a longitudinal axis of the first body 12, 112 at 90 degrees to a longitudinal axis of the second body 22, 122 and the longitudinal axis of the second body 22, 122 at 90 degrees to a longitudinal axis of the third body 32, 132 while the first and second corners 6 a-b are overmoulded. The brace 80 may also prevent the first and second mouldable materials from entering the channels 10, 20, 30, 110, 120, 130 and the slots 41. The first corner 6 a is then placed in between two halves of a mould. A suitable plastic, such as PVC or ABS, is injected into spaces between the two halves of the mould and the first corner 6 a in an overmoulding process forming a first moulded body 50. The plastic injected melts outer surfaces 70 of the bodies 12, 22, 112, 122, therefore fixing the bodies 12, 22, 112, 122 to the first insert 40 a rotationally and axially. In the same process the second corner 6 b is placed in between two halves of a mould or the mould. A suitable thermoplastic material, such as PVC or ABS, is injected into spaces between the two halves of the mould and the second corner 6 b in an overmoulding process forming a second moulded body 60. The plastic injected melts outer surfaces 70 of the bodies 22, 32, 122, 132 and therefore fixes the bodies 22, 32, 122, 132 to the second insert 40 b rotationally and axially. The brace 80 is then removed from the channels 10, 20, 30, 110, 120, 130 and slots 41.

Therefore, the first and second mouldable materials may be a suitable plastic, such as PVC or ABS. The first and second mouldable materials may be different materials. Preferably, the first and second mouldable materials are the same material.

The first and second moulded bodies 50, 60 (moulded bodies) are substantially in the form of a 90 degree elbow. The moulded bodies 50, 60 cover substantially all of an outer surface 7 a-b of the first and second corners 6 a-b. The moulded bodies 50, 60 each include a slot 52, 62 aligned with the open end 42 b of the slots 41 of the inserts 40 a-b and the top end 10 b of the channels 10, 20, 30, 110, 120, 130 as seen in FIG. 10. The moulded bodies 50, 60 provide structural support to the first and second corners 6 a-b. The moulded bodies 50, 60 increase the moment required to break the first and second corners 6 a-b. The moulded bodies 50, 60 include tapers 54, 64 onto outer surfaces 70 of the bodies 12, 22, 32, 112, 122, 132. Outer surfaces 56, 66 of the moulded bodies 50, 60 include rounded corners 58, 68. Outer surfaces 56, 66 of the moulded bodies 50, 60 largely follow the contours of the outer surfaces 70 of the bodies 12, 22, 32, 112, 122, 132.

The first body 12, 112 further includes a hole 72 in a second end 16 b of the first body 12, 112. The third body 32, 132 further includes a hole 72 in a second end 36 b of the third body 12, 112. The holes 72 may have a diameter of between 3 mm and 11 mm.

Preferably, the holes 72 have a diameter of between 5 mm and 9 mm. The cathode plate 2 is adapted for inserting into the edge protector 1, 101, 201, 301. The cathode plate 2 includes holes 82 on a top end 83 a of the cathode plate 2. After the cathode plate 2 is inserted into the edge protector 1, 101, 201, 301, bolts are inserted through the holes 72 in the first and third bodies 12, 32, 112, 132 and through the holes 82 in the cathode plate 2. These bolts fix the edge protector 1, 101, 201, 301 to the cathode plate 2. The edge protector 1, 101, 201, 301 further includes four retainers 90 a-d. The retainers 90 a-d are inserted into the two side ends 10 c-d of the first and third channels 10, 30. The retainers 90 a-d are adapted for insertion into the two side ends 10 c-d of the first and third channels 10, 30 before or after the cathode plate 2 is inserted into the edge protector 1, 101, 201, 302. The retainers 90 a-d apply additional force and friction from the bodies 12, 22, 32, 112, 122, 132 onto the plate portion 2 a of the cathode plate 2 to keep the cathode plate 2 from moving relative to the edge protector 1, 101, 201, 301.

The cathode plate 2 further includes rectangular shaped cut outs 85 a-b in the cathode plates 2 lower corners 86 a-b. The cut outs 85 a-b ensure the corners 86 a-b of the cathode plate 2 can be inserted into the edge protector 1, 101, 201, 301 without interference by build up of material in corners 41 a of the slots 41 of the inserts 40 a-b.

The following passage refers to inserts 140 a-b included in the second and fourth embodiments of the invention. FIG. 13 shows inserts 140 a-b according to the second and fourth embodiments of the invention. The inserts 140 a-b includes tapers 144 c on cylinders 144 a-b of two arms 143 a-b of the inserts 140 a-b. The tapers 144 c extend outwards from the cylinders 144 a-b to a larger diameter edge 144 d. The tapers 144 c create an interference or press fit between the inserts 144 a-b and the features 14, 24 a, 24 b, 34 of the bodies 12, 22, 32, 112, 122, 132. The press fit may assist in keeping the inserts 144 a-b in the same position relative to the bodies 12, 22, 32, 112, 122, 132 when the corners 6 a-b are being overmoulded.

Throughout the specification and claims the word “substantially” refers to greater than 80% by mass. Throughout the specification and claims the word “comprise” and its derivatives are intended to have an inclusive rather than exclusive meaning unless the contrary is expressly stated or the context requires otherwise. That is, the word “comprise” and its derivatives will be taken to indicate the inclusion of not only the listed components, steps or features that it directly references, but also other components, steps or features not specifically listed, unless the contrary is expressly stated or the context requires otherwise.

In the present specification, terms such as “apparatus”, “means”, “device” and “member” may refer to singular or plural items and are terms intended to refer to a set of properties, functions or characteristics performed by one or more items or components having one or more parts. It is envisaged that where an “apparatus”, “means”, “device” or “member” or similar term is described as being a unitary object, then a functionally equivalent object having multiple components is considered to fall within the scope of the term, and similarly, where an “apparatus”, “assembly”, “means”, “device” or “member” is described as having multiple components, a functionally equivalent but unitary object is also considered to fall within the scope of the term, unless the contrary is expressly stated or the context requires otherwise.

Orientational terms used in the specification and claims such as vertical, horizontal, top, bottom, upper and lower are to be interpreted as relational and are based on the premise that the component, item, article, apparatus, device or instrument will usually be considered in a particular orientation, typically with the second body 22,122 lowermost.

It will be appreciated by those skilled in the art that many modifications and variations may be made to the methods of the invention described herein without departing from the spirit and scope of the invention. 

1. An edge protector mountable to a cathode plate, the edge protector comprising a set of elongate channels, each elongate channel defining a slot, the set of elongate channels including a first and second channel adapted to receive and cover respective side edges of the cathode plate, and a third channel adapted to receive and cover a lower edge of the cathode plate, the first, second and third channels beings channels of a first, second and third body, respectively, wherein the edge protector further includes: a first and second insert, the first insert being adapted to be placed into or over a feature of a first end of the first body and a feature of a first end of the second body to form a first corner, the second insert being adapted to be placed into or over a feature of a second end of the second body and a feature of a first end of the third body to form a second corner; and first and second corner over moldings adapted to seal the first and second corners, the first corner over molding being separate to the second corner over molding.
 2. The edge protector as claimed in claim 1, wherein, the first, second and third channels (channels) have a transverse cross section which is substantially cruciform in shape.
 3. The edge protector as claimed in claim, wherein, the cruciform shape includes four ends, the four ends including an open end which is adapted to receive the cathode plate and three closed ends, the three closed ends including a first closed end opposite the open end and two side ends, the two side ends each adapted to receive a seal.
 4. The edge protector as claimed in claim 1, wherein the first and second inserts each include a slot adapted to receive the cathode plate.
 5. The edge protector as claimed in claim 1, wherein the first corner over moldings is formed in an over molding process in which injected plastic melts an outer surface of the first body, therefore fixing the first body to the first insert rotationally and axially.
 6. The edge protector as claimed in claim 1, wherein the first and second bodies are formed in an over moulding of the first and second corners whereby the respective outer surfaces of the first and second bodies are melted.
 7. The edge protector as claimed in claim 1, wherein the first and second corners include the first body aligned or oriented at an angle of between 80 and 100 degrees relative to the alignment or orientation of the second body, and the second body is aligned or oriented at an angle of between 80 and 100 degrees relative to the alignment or orientation of the third body.
 8. The edge protector as claimed in claim 1, wherein all of the components of the edge protector are made of plastic.
 9. The edge protector as claimed in claim 1, wherein the feature of the first end of the first body is substantially in the form of a cylinder.
 10. The edge protector as claimed in claim 1, wherein the first insert includes an interference or press fit into the feature of the first body.
 11. The edge protector as claimed in claim 1, wherein the first channel is substantially uniform along its length.
 12. The edge protector as claimed in claim 1, wherein a transverse cross section of the first channel is substantially identical to a transverse cross section of each of the second and third channels.
 13. The edge protector as claimed in claim 1, wherein the open end of each of the first, second and third channels includes a taper from a larger thickness of the channel to a smaller thickness of the channel at an open edge of each of the channel, the open end of each of the channel being adapted to receive the cathode plate.
 14. The edge protector as claimed in claim 1, wherein the first and third bodies include holes adapted to line up with holes in the cathode plate such that bolts can be inserted through the holes in the first and third bodies and the cathode plate.
 15. (canceled)
 16. A method of manufacturing an edge protector for a cathode plate as claimed in claim 1, comprising the steps of: (a) receiving and covering the respective side edges of the cathode plate with the first and second elongate channels; (b) receiving and covering a lower edge of the cathode plate with the third elongate channel; (c) placing the respective first and second inserts into or over the respective feature of the first and second ends of the respective first and second bodies to form the corresponding first and second corners; (d) placing the second insert into or over the feature of the second end of the second body and the feature of a first end of the third body to complete the second corner; and (e) over molding the first and second corners to seal the first and second corners.
 17. A method as claimed in claim 16, further comprising the step of: (f) inserting a brace into the first second and third channels and slots to hold a longitudinal axis of the first body at 90 degrees to a longitudinal axis of the second body and the longitudinal axis of the second body at 90 degrees to a longitudinal axis of the third body whilst the first and second corners are over-molded.
 18. A method as claimed in claim 17, further comprising the step of: (g) injecting a suitable plastic into spaces between the two halves of the mould and the first corner in an over-molding process forming the first molded body.
 19. A method as claimed in claim 18, further comprising the step of: (h) melting the plastic outer surfaces of the bodies, therefore fixing the bodies to the first insert rotationally and axially.
 20. A method as claimed in claim 19, further comprising the step of: (i) placing the second corner between two halves of a mold and injecting plastic into spaces between the two halves of the mold and the second corner in an over molding process forming a second molded body.
 21. A method as claimed in claim 20, further comprising the steps of: (j) injecting the plastic to melt the outer surfaces of the first, second and third bodies and fixing same to the second insert rotationally and axially; and (k) removing the brace from the first, second and third channels and slots. 